Profitability of Chemically Cross-Linked Collagen Scaffold Production Using Bovine Pericardium: Revaluing Waste from the Meat Industry for Biomedical Applications
Abstract
:1. Introduction
2. Materials and Methods
2.1. Bovine Pericardium Composition
2.2. Process Description
2.2.1. Decellularization Stage
2.2.2. Crosslinker Synthesis
2.2.3. Crosslinking
2.2.4. Washing
2.2.5. Freezing and Drying
2.3. Scenarios
2.4. Financial Investment and Assumptions
2.4.1. Net Present Value Method (NPV)
2.4.2. Economic Considerations
3. Results
Comparison with Actual Commercial Products
4. Discussion
5. Conclusions
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
Appendix A
Appendix B
Equipment | Equipment Specifications | ||||||
---|---|---|---|---|---|---|---|
Specifications | 5000 BPU.mth−1 | 15,000 BPU.mth−1 | 25,000 BPU.mth−1 | ||||
P-3/V-101 (Stirring Tank) | Volume | 68.04 | L | 204.13 | L | 340.21 | L |
Height/Diameter ratio | 3 | n/a | 3 | n/a | 3 | n/a | |
Height | 0.92 | m | 1.327 | m | 5.164 | m | |
Diameter | 0.307 | m | 0.442 | m | 1.721 | m | |
Design pressure | 1.52 | bar | 1.52 | bar | 1.52 | bar | |
Purchase cost | 38.023 | $ | 54.677 | $ | 65.837 | $ | |
Material | SS316 | SS316 | SS316 | ||||
Energy consumption | 26.45 | kWh. yr−1 | 79.37 | kWh. yr−1 | 132.28 | kWh. yr−1 | |
Operating temperature | 25.3 | °C | 25.3 | °C | 25,3 | °C | |
Operating pressure | 1.013 | bar | 1.013 | bar | 1.013 | bar | |
Operating volume | 61.24 | L | 183.72 | L | 306.19 | L | |
P-1/DS-101 (Centrifuge) | Separation capacity (Factor Sigma Σ) | 108.49 | m2 | 325.46 | m2 | 542.43 | m2 |
Rated performance | 1.28 | L/h | 3.83 | L/h | 6.39 | L/h | |
Purchase cost | 4.000 | $ | 4.000 | $ | 4.000 | $ | |
Material | SS316 | SS316 | SS316 | ||||
Minimum solid particle diameter | 1 × 10−6 | m | 1 × 10−6 | m | 1 × 10−6 | m | |
Sedimentation efficiency | 30% | 30% | 30% | ||||
Operating temperature | 25 | °C | 25 | °C | 25 | °C | |
Energy consumption | 10.271.50 | kWh. yr−1 | 15939.79 | kWh. yr−1 | 19553.38 | kWh. yr−1 | |
P-19/V-108 (Stirring Tank) | Volume | 2.52 | L | 7.56 | L | 12.59 | L |
Height/Diameter ratio | 3 | n/a | 3 | n/a | 3 | n/a | |
Height | 0.307 | m | 0.442 | m | 0.525 | m | |
Diameter | 0.102 | m | 0.147 | m | 0.175 | m | |
Design pressure | 1.52 | bar | 1.52 | bar | 1.52 | bar | |
Purchase cost | 17.892 | $ | 21.670 | $ | 24.189 | $ | |
Material | SS316 | SS316 | SS316 | ||||
Energy consumption | 0 | kWh. yr−1 | 0 | kWh. yr−1 | 0 | kWh. yr−1 | |
Operating temperature | 25 | °C | 25 | °C | 25 | °C | |
Operating pressure | 1.013 | bar | 1.013 | bar | 1.013 | bar | |
Operating volume | 2.27 | L | 6.8 | L | 11.33 | L | |
P-20/V-105 (Stirring Tank) | Volume | 42.88 | L | 128.63 | L | 214.38 | L |
Height/Diameter ratio | 3 | n/a | 3 | n/a | 3 | n/a | |
Height | 0.789 | m | 1.138 | m | 1.349 | m | |
Diameter | 0.263 | m | 0.379 | m | 0.45 | m | |
Design pressure | 1.52 | bar | 1.52 | bar | 1.52 | bar | |
Purchase cost | 33.145 | $ | 46.644 | $ | 55.639 | $ | |
Material | SS316 | SS316 | SS316 | ||||
Energy consumption | 0 | kWh. yr−1 | 0 | kWh. yr−1 | 0 | kWh. yr−1 | |
Operating temperature | 25 | °C | 25 | °C | 25 | °C | |
Operating pressure | 1.013 | bar | 1.013 | bar | 1.013 | bar | |
Operating volume | 38.59 | L | 115.76 | L | 192.94 | L | |
P-4/DS-102 (Centrifuge) | Separation capacity (Factor Sigma Σ) | 136.58 | m−2 | 409.75 | m−2 | 682.91 | m−2 |
Rated performance | 1.61 | L/h | 4.82 | L/h | 8.04 | L/h | |
Purchase cost | 4.000 | $ | 4.000 | $ | 4.000 | $ | |
Material | SS316 | SS316 | SS316 | ||||
Minimum solid particle diameter | 1 × 10−6 | m | 1 × 10−6 | m | 1 × 10−6 | m | |
Sedimentation efficiency | 30% | 30% | 30% | ||||
Operating temperature | 25 | °C | 25 | °C | 25 | °C | |
Energy consumption | 11262.69 | kWh. yr−1 | 17477.95 | kWh. yr−1 | 21440.26 | kWh. yr−1 | |
P-5/R-101 (Stirred Reactor) | Volume | 0.13 | L | 0.38 | L | 0.63 | L |
Height/Diameter ratio | 2.5 | 2.5 | 2.5 | ||||
Height | 0.102 | m | 0.147 | m | 0.171 | m | |
Diameter | 0.041 | m | 0.059 | m | 0.068 | m | |
Design pressure | 1.52 | bar | 1.52 | bar | 1.52 | bar | |
Purchase cost | 71 | $ | 73 | $ | 98 | $ | |
Material | Glass | Glass | Glass | ||||
Energy consumption | 0.04 | kWh. yr−1 | 0.12 | kWh. yr−1 | 0.2 | kWh. yr−1 | |
Operating temperature | 100 | °C | 100 | °C | 100 | °C | |
Operating pressure | 1.013 | bar | 1.013 | bar | 1.013 | bar | |
Operating volume | 0.11 | L | 0.34 | L | 0.56 | L | |
P-8/R-102 (Stirred Reactor) | Volume | 0.25 | L | 0.61 | L | 1.01 | L |
Height/Diameter ratio | 2.5 | 2.5 | 2.5 | ||||
Height | 0.126 | m | 0.169 | m | 0.201 | m | |
Diameter | 0.05 | m | 0.068 | m | 0.08 | m | |
Design pressure | 1.52 | bar | 1.52 | bar | 1.52 | bar | |
Purchase cost | 137 | $ | 112 | $ | 157 | $ | |
Material | Glass | Glass | Glass | ||||
Energy consumption | 0.07 | kWh. yr−1 | 0.2 | kWh. yr−1 | 0.33 | kWh. yr−1 | |
Operating temperature | 40 | °C | 40 | °C | 40 | °C | |
Operating pressure | 1.013 | bar | 1.013 | bar | 1.013 | bar | |
Operating volume | 0.18 | L | 0.55 | L | 0.91 | L | |
P-7/V-103 (Stirred Tank) | Volume | 3.96 | L | 11.89 | L | 19.81 | L |
Height/Diameter ratio | 3 | n/a | 3 | n/a | 3 | n/a | |
Height | 0.357 | m | 0.515 | m | 0.61 | m | |
Diameter | 0.119 | m | 0.172 | m | 0.203 | m | |
Design pressure | 1.52 | bar | 1.52 | bar | 1.52 | bar | |
Purchase cost | 2.171 | $ | 2.192 | $ | 3.074 | $ | |
Material | Glass | Glass | Glass | ||||
Energy consumption | 0 | kWh. yr−1 | 0 | kWh. yr−1 | 0 | kWh. yr−1 | |
Operating temperature | 25 | °C | 25 | °C | 25 | °C | |
Operating pressure | 1.013 | bar | 1.013 | bar | 1.013 | bar | |
Operating volume | 3.57 | L | 10.7 | L | 17.83 | L | |
P-13/V-104 (Stirred Tank) | Volume | 0.22 | L | 0.66 | L | 1.1 | L |
Height/Diameter ratio | 3 | n/a | 3 | n/a | 3 | n/a | |
Height | 0.136 | m | 0.196 | m | 0.233 | m | |
Diameter | 0.045 | m | 0.065 | m | 0.078 | m | |
Design pressure | 1.52 | bar | 1.52 | bar | 1.52 | bar | |
Purchase cost | 120 | $ | 121 | $ | 171 | $ | |
Material | Glass | Glass | Glass | ||||
Energy consumption | 0 | kWh. yr−1 | 0 | kWh. yr−1 | 0 | kWh. yr−1 | |
Operating temperature | 25 | °C | 25 | °C | 25 | °C | |
Operating pressure | 1.013 | bar | 1.013 | bar | 1.013 | bar | |
Operating volume | 0.2 | L | 0.59 | L | 0.99 | L | |
P-18/R-103 (Stirred Reactor) | Volume | 4.92 | L | 14.76 | L | 24.61 | L |
Height/Diameter ratio | 2.5 | 2.5 | 2.5 | ||||
Height | 0.34 | m | 0.49 | m | 0.581 | m | |
Diameter | 0.136 | m | 0.196 | m | 0.232 | m | |
Design pressure | 1.52 | bar | 1.52 | bar | 1.52 | bar | |
Purchase cost | 20.000 | $ | 25.140 | $ | 28.526 | $ | |
Material | SS316 | SS316 | SS316 | ||||
Energy consumption | 1.59 | kWh. yr−1 | 4.78 | kWh. yr−1 | 7.97 | kWh. yr−1 | |
Operating temperature | 25 | °C | 25 | °C | 25 | °C | |
Operating pressure | 1.013 | bar | 1.013 | bar | 1.013 | bar | |
Operating volume | 4.43 | L | 13.29 | L | 22.15 | L | |
P-16/V-107 (Stirred Tank) | Volume | 0.76 | L | 2.27 | L | 3.79 | L |
Height/Diameter ratio | 3 | n/a | 3 | n/a | 3 | n/a | |
Height | 0.206 | m | 0.296 | m | 0.351 | m | |
Diameter | 0.069 | m | 0.099 | m | 0.117 | m | |
Design pressure | 1.52 | bar | 1.52 | bar | 1.52 | bar | |
Purchase cost | 15.608 | $ | 17.636 | $ | 19.072 | $ | |
Material | SS316 | SS316 | SS316 | ||||
Energy consumption | 0 | kWh. yr−1 | 0 | kWh. yr−1 | 0 | kWh. yr−1 | |
Operating temperature | 25 | °C | 25 | °C | 25 | °C | |
Operating pressure | 1.013 | bar | 1.013 | bar | 1.013 | bar | |
Operating volume | 0.68 | L | 2.05 | L | 3.41 | L | |
P-17/FDR-101 (Freeze dryer) | Sublimation capacity per cycle | 10.68 | kg | 32.04 | kg | 53.399 | kg |
Tray area | 0.373 | m−2 | 1.119 | m−2 | 1.864 | m−2 | |
Purchase cost | 20.000 | $ | 20.000 | $ | 20.000 | $ | |
Material | SS316 | SS316 | SS316 | ||||
Final solid temperature | 12 | °C | 12 | °C | 12 | °C | |
Sublimation rate | 1 | mm/h | 1 | mm/h | 1 | mm/h | |
Energy consumption | 503.36 | kWh. yr−1 | 1510.09 | kWh yr−1 | 2516.81 | kWh yr−1 |
Appendix C
3A. Total Plant Direct Cost (TPDC) (Physical Cost) | 5000 BPU.mth−1 | 15,000 BPU.mth−1 | 25,000 BPU.mth−1 |
---|---|---|---|
Total Plant Direct Cost (TPDC) (physical cost) | |||
1. Equipment Purchase Cost | 197,000 | 248,000 | 284,000 |
2. Installation | 66,000 | 84,000 | 96,000 |
3. Process Piping | 69,000 | 87,000 | 99,000 |
4. Instrumentation | 79,000 | 99,000 | 114,000 |
5. Insulation | 6,000 | 7,000 | 9,000 |
6. Electrical | 20,000 | 25,000 | 28,000 |
7. Buildings | 89,000 | 112,000 | 128,000 |
8. Yard Improvement | 30,000 | 37,000 | 43,000 |
9. Auxiliary Facilities | 79,000 | 99,000 | 114,000 |
TPDC | 634,000 | 799,000 | 914,000 |
Total Plant Indirect Cost (TPIC) | |||
10. Engineering | 158,000 | 200,000 | 228,000 |
11. Construction | 222,000 | 280,000 | 320,000 |
TPIC | 380,000 | 479,000 | 548,000 |
Total Plant Cost (TPC = TPDC + TPIC) | |||
TPC | 1,014,000 | 1,279,000 | 1,462,000 |
Contractor’s Fee & Contingency (CFC) | |||
12. Contractor’s Fee | 51,000 | 64,000 | 73,000 |
13. Contingency | 101,000 | 128,000 | 146,000 |
CFC = 12 + 13 | 152,000 | 192,000 | 219,000 |
Direct Fixed Capital Cost (DFC = TPC + CFC) | |||
DFC | 1,166,000 | 1,470,000 | 1,681,000 |
Bulk Material | Unit Cost ($/kg) | Source |
---|---|---|
Sodium bisulphite | 24.85 | Sigma-Aldrich ® |
EDTA Disodium | 193.80 | Sigma-Aldrich ® |
Ethyl alcohol | 0.75 | Sigma-Aldrich ® |
HDI | 155.40 | Sigma-Aldrich ® |
MgO | 895.00 | Sigma-Aldrich ® |
Phosphate-buffer | 4.00 | Sigma-Aldrich ® |
Polyethyleneglycol | 72.00 | Sigma-Aldrich ® |
TEOS | 83.00 (L STP) | Sigma-Aldrich ® |
Triton-X-100 | 1.50 | Sigma-Aldrich ® |
Tris-HCl | 125 | Sigma-Aldrich ® |
Unit cost ($/mg) | ||
RNase | 0.34 | Sigma-Aldrich ® |
DNase | 1.34 | Sigma-Aldrich ® |
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Equation | Oligomer Structure | Yield (%) | Equation # |
---|---|---|---|
Reactions involved in the synthesis of the crosslinker (oligomerization) | |||
Trimer | 70 | (1) | |
Pentamer | 80 | (2) | |
Heptamer | 99 | (3) | |
Reactions used to block oligourethane | |||
90 | (4) | ||
90 | (5) | ||
90 | (6) | ||
90 | (7) | ||
Crosslinking reactions. | |||
90 | (8) | ||
90 | (9) | ||
90 | (10) | ||
90 | (11) |
5000 BPU.mth−1 | 15,000 BPU.mth−1 | 25,000 BPU.mth−1 | Units | |
---|---|---|---|---|
Total capital investment | 1,258,000 | 1,613,000 | 1,872,000 | USD |
Operating cost | 612,560 | 1,074,320 | 1,515,280 | USD/yr |
Revenues | 783,000 | 1,305,000 | 1,740,000 | USD/yr |
Cost basis annual rate | 750.00 | 2,250 | 3,750 | kg MP/yr |
Net unit production cost | 784.57 | 458.94 | 388.26 | USD/kg MP |
Unit production revenue | 1,043.75 | 579.86 | 463.89 | USD/kg MP |
Unit production revenue | 0.16 ± 0.078 | 0.086 ± 0.043 | 0.069 ± 0.035 | USD/cm2 MP |
Gross margin | 24.79 | 20.85 | 16.30 | % |
Return on investment | 20.38 | 21.31 | 19.90 | % |
Payback time | 4.91 | 4.69 | 5.03 | years |
IRR (After taxes) | 13.06 | 14.34 | 13.25 | % |
NPV (at 7.0% interest) | 523,000 | 817,000 | 787,000 | $ |
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Share and Cite
Cruz Bosques, J.A.d.l.; Ibarra Sánchez, J.d.J.; Mendoza-Novelo, B.; Segovia-Hernandez, J.G.; Molina-Guerrero, C.E. Profitability of Chemically Cross-Linked Collagen Scaffold Production Using Bovine Pericardium: Revaluing Waste from the Meat Industry for Biomedical Applications. Polymers 2023, 15, 2797. https://doi.org/10.3390/polym15132797
Cruz Bosques JAdl, Ibarra Sánchez JdJ, Mendoza-Novelo B, Segovia-Hernandez JG, Molina-Guerrero CE. Profitability of Chemically Cross-Linked Collagen Scaffold Production Using Bovine Pericardium: Revaluing Waste from the Meat Industry for Biomedical Applications. Polymers. 2023; 15(13):2797. https://doi.org/10.3390/polym15132797
Chicago/Turabian StyleCruz Bosques, José Arturo de la, José de Jesús Ibarra Sánchez, Birzabith Mendoza-Novelo, Juan Gabriel Segovia-Hernandez, and Carlos Eduardo Molina-Guerrero. 2023. "Profitability of Chemically Cross-Linked Collagen Scaffold Production Using Bovine Pericardium: Revaluing Waste from the Meat Industry for Biomedical Applications" Polymers 15, no. 13: 2797. https://doi.org/10.3390/polym15132797